FUSION Impact Screen Protector: How It’s Made

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We often get asked what makes our latest product, our patented Fusion Impact Screen Protector, so unique, and how we make it. For those of you who love technical details, we are happy to share them. Just beware of our passion for plastics — it might be contagious!

FUSION is the combination of three powerful and unique layers, each adding a specialized strength to the overall product. We call it TriACTIVE protection. All three layers combined add up to less than a half of the thickness of a credit card. We were also able to achieve remarkable results in application process, clarity, and glass-like smoothness. We invented, developed, and tested it in our Philadelphia facility. This is how it is made.

TOP LAYER: Polyurethane for scratch resistance

When it comes to protecting surfaces from scratches, polyurethane is the winner. Somewhat counterintuitive, compared to hard materials like glass, polyurethane is soft and stretchy. Yet, the composition of the film is so dense, it makes it tough. When you zoom in close, it looks like a giant memory foam. If you dig your fingernail into it, you’ll notice that you’ve left a depression. This indent, over time, will reshape itself and disappear, or self heal. This is also why it is so hard for a scratch to go through the material.

Take a look at the video below where we test three materials (Tempered Glass, Polyurethane, and PET) used for screen protection today. We are using the H8 pen from Deluxe Hardness Pick Set from Mineralab and are applying the same pressure to all three materials to see how they react to it.

Tempered glass is on the left; FUSION is in the middle (top layer is polyurethane); PET Plastic Screen Protector is on the right.

MIDDLE LAYER: PET to spread out impacts

This is an incredibly stiff, rigid material — so kind of like hitting a hammer on a block of wood, this rigid layer spreads the energy from any impact (like dropping your phone) across a much wider surface. However, as the video shows, PET isn’t really good at stopping scratches — just like wood, it scratches really easily, which is why we made that urethane top layer.

BOTTOM LAYER: Self-Wetting Adhesive

This layer makes it easy to apply the screen protector for as many times as needed without using any kind of squeegee or spray. It feels more like a gel than a “sticky” adhesive — because it’s so soft and has that “gel” property, it conforms to the screen and acts like a liquid when you put it on the screen — even though it’s just a super-soft solid. And, it’s really tough – you can even wash it with plain old dish detergent and hot water, and re-use it.

Putting it all together

We’re absolutely dedicated to domestic manufacturing, so most of our raw materials are sourced in the USA (The PET is not — but we’re looking for great domestic partners on this. Email sourcing@clear-coat.com if you’re interested), and the process of sandwiching these all together using over a ton of pressure happens right here in Philadelphia. We then cut the film into custom screen protectors using a specialized laser. In the final step we check for any errors, package it, and ship it out to our customers.

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About Eric Griffin

Eric Griffin is co-founder at Clear-Coat, and has been a big tech enthusiast since his first Mac Classic when he was 8. Aside from gadgets & business, Eric loves to design, cook, bike, snowboard, rehab real estate, and make espresso. You can reach Eric on Twitter: @griffslinks and Google Plus: +Eric Griffin.

I am also very interested for this product on an Xperia Z3 Compact– preferably front and back!
If it’s not possible, I wonder if you can suggest an alternative; tempered glass has been protecting my screen but itself is covered in cracks from the tiniest drops and taps.

Hi it looks good I just got a glass one for my phone but yours looked better and I decided to see about getting one but was a shame to see the only options were iPhone or Samsung I have a Sony Xperia z3 compact if you ever produce a screen for.that model plz let me know and I would get one

Hi
Its an amazing screen protector.As Fusion is easy to install but the best is that the screen protector is washable so if you get too much dust under screen protector or something during the install goes awry, you can easy take it off, wash it and re-apply. The re-applicability of the screen protector, coupled with their warranty makes the Fusion screen protector a great product.

After seeing the video, I agreed that your fusion impact screen protector is better in handling scratches but I still think tempered glass is optically superior than plastic. The screen colors and details are sharper and the contrast is better than plastic. What do you think? Do you have a video that shows otherwise?